Archive for the ‘engine’ Tag

XS650: Troubleshooting Manual   Leave a comment

If you have ended here and not where you want to go – VOU HAVE A VIRUS ON YOUR COMPUTER … do us both a favour and scroll back to my blog post Virus. Please read this then do a search as suggested.

Yamaha Troubleshooting Manual

In 3 languages. English. French. German

Troubleshooting Manual

Yamaha Troubleshooting Manual

Trouble Shooting

– hopefully this can prove organic … comments and suggestions – correcting, extending
– an engine is basically an air pump – 4 stroke …  suck, squeeze, bang, blow
– add fuel, timing and spark = internal combustion engine
– break this system anywhere and you wont get much action

– so your engine turns over ? wont start
– what have you done ? what have you changed, altered, played with, unfixed ?
– air ? fuel ? spark ? …all in the correct ammount and moment ?
– don’t panic…turn the key and petcock/s off, step back …take a breath-deep, go do something you really enjoy for a couple of minutes…

  •  fuses ? kill switch ?
  •  battery ? 12.6 V ? put it on charge, brushes ? check charging system
  • power to coil/s ? points spark ? plugs ?
  • filters ?
  • fuel to carbs ? bowls ? cylinders ? floods ?
  • compression ? leak-down test ?

·

  •    adjust your cam chain … can readjust warm once you get her running
  •       set your tappets
  •       set your points if you have them .. plugs

 

– once you get this far she should be at least spitting and farting enough to attempt setting your carbs …

  • if she wont idle, look for air leaks ? atu ? massage her pilot jet circuits
  • once you can get idle, do the idle speed screw/pilot air screw dance
  • smooth transition through to full throttle ?
  • synchronise

Electric Troubleshooting

Carburetor Troubleshooting

Starting System Troubleshooting

Engine Troubleshooting

Oil Troubleshooting

Clutch and Gearbox Troubleshooting

Frame Troubleshooting

XS650: Engine Nuts n Bolts   Leave a comment

Been thinking about tarting one of the old girls up a little. Nuts n Bolts. But which?

  • Alu?
  • Stainless Steel?
  • Titanium?
  • Phillips Screw type?
  • Hex socket(Allen key)?
  • Hex Head?
  • Race Spec?

Not racing so I dont need them drilled. Weight isn’t really a factor so I can’t justify the expense of Titanium. Aluminium? Stainless steel?

Pro Bolt has an interesting selection. Outlets in the UK, USA, Australia, Germany, Denmark, France, South Africa.

 

aluminium, hex socket – allen key … gold, silver, red, purple, orange, grey, black, blue

 

stainless steel … hex socket – tapered head (allen key)

 

stainless steel … flanged head hex bolt

 

Titanium … race spec – drilled … flanged head hex bolt … silver, purple, gold, blue

 

aluminium … race spec – drilled … hex bolt

 

titanium banjo bolt – single … 10mm – hex socket (allen key)

Next problem. List of required items. Went through an old engine. Put this list together…Haven’t checked it right through so may not be 100% correct. XS650E.

 

5.0 x 0.8mm
   Alternator Cover

2

5 X 10 Hex socket
   Carb Top

8

5 x 16 Phillips

Washer

8

5mm Plain
6.0 x 1.0mm
HEAD:
   Breather Box

4

4

6×60(large)

6×25(small)

Hex Socket
   Points/ATU Cover

4

6 x 20
   Bolt

1

6 x 35 Hex Bolt

Washer

   1 6mm Plain
   Tri. Tappet Cover

9

6mm Crown Nut

Washer

9

6mm Plain
BARREL:
   Cam Chain Adj

4

6 x 18 Hex Bolt
   .. with shoulder

2

6 x 19 Hex Bolt

Washer

6

6mm Plain
   Front Guide

2

2

6x20M10-special Hex Bolt

Washer

Washer

2

2

6mm/11mm Copper-Plain
   Carb Boot

4

6 x 20 Hex Socket
CRANKCASE:
   Starter Cover

6

6 x 25 Hex Socket
   Oil Sump Cover

6

6 x 25 Hex Socket
   Gear Lever

1

6 x 20 Hex Bolt
ALTERNATOR  SIDECASE:

4

6 x 25 Hex Socket
   Bolt

2

6 x 40 Hex Socket
CLUTCH  SIDECASE:

4

6 x 75 Hex Socket
   Bolt

1

6 x 40 Hex Socket
   Bolt

7

6 x 25 Hex Socket
8.0 x 1.25mm
HEAD:
   Squ. Tappet Cover

4

8mm Crown Nut
   Bolt

4

8 x 60 Hex Bolt
   Bolt

2

8 x 35 Hex Bolt

Washer

10

8mm Plain
CRANKCASE:
   Bolt

2

8 x 75 Hex Bolt
   Bolt

1

8 x 55 Hex Bolt
   Bolt

1

8 x 90 Hex Bolt
   Nut

8

8mm Short Open
   Nut

6

8mm Long Crown

Washer

12

8mm Plain
Kickstart

1

8 x 30 Hex Bolt
Starter

2

8 x 35 Hex Bolt
Starter

2

8 x 35 Hex Bolt-flank

Washer

4

8mm Plain

Washer

4

8mm Spring
10 x 1.25mm
HEAD:

8

10mm Crown Nut

Washer

8

22×10.5x4mm Copper/Brass Plain
Banjo Bolts ..Oil

2

10mm Single

Washer

4

10mm Copper Plain

Posted February 29, 2012 by xscafe in Manual - Other, Motor - Cases

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XS650: Crankcase Cleaning   Leave a comment

Was flicking through youtube and found this:

The observant will notice, rods are still attached. This is a non-european motor with shorter rods.

Naturlich, it’s way easier to do your cleaning before removing from frame-just like the front sprocket nut, eh

Posted January 20, 2011 by xscafe in Motor - Cases

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XS650: Torque Settings   Leave a comment

I’ve simply copied this out of a Yamaha Manual. There may be mistakes. If so point them out. Also any that aren’t there.

torque

 

torque

 

engine case torque sequence

 

head nut torque sequence